EP3848182A1 - Coated powder for additive manufacturing - Google Patents

Coated powder for additive manufacturing Download PDF

Info

Publication number
EP3848182A1
EP3848182A1 EP21150187.9A EP21150187A EP3848182A1 EP 3848182 A1 EP3848182 A1 EP 3848182A1 EP 21150187 A EP21150187 A EP 21150187A EP 3848182 A1 EP3848182 A1 EP 3848182A1
Authority
EP
European Patent Office
Prior art keywords
polymer material
coating
base polymer
coated powder
powder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP21150187.9A
Other languages
German (de)
French (fr)
Other versions
EP3848182B1 (en
Inventor
Nishant Sinha
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
Original Assignee
Boeing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Boeing Co filed Critical Boeing Co
Publication of EP3848182A1 publication Critical patent/EP3848182A1/en
Application granted granted Critical
Publication of EP3848182B1 publication Critical patent/EP3848182B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/12—Powdering or granulating
    • C08J3/126—Polymer particles coated by polymer, e.g. core shell structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0002—Organic membrane manufacture
    • B01D67/0004—Organic membrane manufacture by agglomeration of particles
    • B01D67/00045—Organic membrane manufacture by agglomeration of particles by additive layer techniques, e.g. selective laser sintering [SLS], selective laser melting [SLM] or 3D printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0041—Inorganic membrane manufacture by agglomeration of particles in the dry state
    • B01D67/00415—Inorganic membrane manufacture by agglomeration of particles in the dry state by additive layer techniques, e.g. selective laser sintering [SLS], selective laser melting [SLM] or 3D printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/08—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
    • B05D5/083—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface involving the use of fluoropolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/80—Plants, production lines or modules
    • B22F12/82—Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/171—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
    • B29C64/176—Sequentially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/171—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
    • B29C64/182—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects in parallel batches
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/227—Driving means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/245—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/25—Housings, e.g. machine housings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y99/00—Subject matter not provided for in other groups of this subclass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
    • C08G73/10—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04—PVOH, i.e. polyvinyl alcohol
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2279/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain not provided for in groups B29K2261/00 - B29K2277/00, as reinforcement
    • B29K2279/08—PI, i.e. polyimides or derivatives thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2329/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
    • C08J2329/02—Homopolymers or copolymers of unsaturated alcohols
    • C08J2329/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2379/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen, or carbon only, not provided for in groups C08J2361/00 - C08J2377/00
    • C08J2379/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C08J2379/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2429/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
    • C08J2429/02—Homopolymers or copolymers of unsaturated alcohols
    • C08J2429/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/70—Microphotolithographic exposure; Apparatus therefor
    • G03F7/70416—2.5D lithography
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
    • G03G2215/00—Apparatus for electrophotographic processes
    • G03G2215/20—Details of the fixing device or porcess
    • G03G2215/2003—Structural features of the fixing device
    • G03G2215/2048—Surface layer material
    • G03G2215/2054—Inorganic filler, e.g. silica powder
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49023—3-D printing, layer of powder, add drops of binder in layer, new powder
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49246—3-D printing, layer of powder, add drops of binder in layer, new powder
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01—Dielectrics
    • H05K2201/0137—Materials
    • H05K2201/015—Fluoropolymer, e.g. polytetrafluoroethylene [PTFE]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702—For plural parts or plural areas of single part
    • Y10T156/1712—Indefinite or running length work
    • Y10T156/1722—Means applying fluent adhesive or adhesive activator material between layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1798—Surface bonding means and/or assemblymeans with work feeding or handling means with liquid adhesive or adhesive activator applying means

Definitions

  • the present disclosure relates to additive manufacturing apparatus and methods, and particularly to powder-based additive manufacturing.
  • the additive manufacturing process disclosed herein can be useful in producing parts including environmental control ducts, door panels, tools, jigs, fixtures, and the like. Examples of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive, and for example a casing used for auxiliary power units (APUs).
  • APUs auxiliary power units
  • Parts and other components may be manufactured using various manufacturing techniques depending on the performance requirements of the parts and the availability of manufacturing equipment.
  • Selective laser sintering (SLS) and selective laser melting (SLM) are powder-based additive manufacturing techniques that may be used to build components, in which a layer of powder is maintained at an elevated temperature and is selectively sintered or melted using a laser. Once a first build layer has been formed, successive build layers are formed on top of the first build layer using a similar process until the desired three-dimensional object is complete. Powders used in these processes are typically formed of thermoplastic, polycarbonate, or other similarly configured material. Powder-based additive manufacturing, such as SLS and SLM, may introduce voids between powder particles within a build layer and between adjacent build layers formed during the process, thereby resulting in an object with reduced structural integrity.
  • a coated powder for use in an additive manufacturing process.
  • the coated powder includes a base polymer layer formed of a base polymer material having a first dielectric loss factor, and a coating polymer layer surrounding the base polymer layer and formed of a coating polymer material having a second dielectric loss factor, wherein the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
  • a method of fabricating a coated powder for use in an additive manufacturing process includes advancing a plurality of powder particles through a chamber, each of the plurality of powder particles being formed of a base polymer material, applying a liquid coating to an exterior of each of the plurality of powder particles, the liquid coating being formed of a coating polymer material, and drying the liquid coating on the plurality of powder particles to form a plurality of coated powder particles.
  • Each of the plurality of coated powder particles comprises a base polymer layer formed by the powder particle and a coating polymer layer formed by the liquid coating after drying.
  • a method of fabricating an object by fused powder fabrication includes forming a coated powder by advancing a plurality of powder particles through a chamber, each of the plurality of powder particles being formed of a base polymer material, applying a liquid coating to an exterior of each of the plurality of powder particles, the liquid coating being formed of a coating polymer material, and drying the liquid coating on the plurality of powder particles to form a plurality of coated powder particles, so that each of the plurality of coated powder particles comprises a base polymer layer formed by the powder particle and a coating polymer layer formed by the liquid coating after drying.
  • the method further includes depositing the coated powder in a first build layer on a substrate, heating selected portions of the first build layer, depositing the coated powder in a second build layer on the substrate and over the first build layer, heating selected portions of the second build layer, and dielectrically heating at least the coating polymer layer of the coated powder in the selected portions of the first and second build layers using electromagnetic radiation, thereby to fuse adjacent particles of the coated powder across an interface area.
  • the following detailed description is directed to powder-based additive manufacturing technologies, such as selective laser sintering (SLS) or selective laser melting (SLM).
  • SLS selective laser sintering
  • SLM selective laser melting
  • the examples disclosed herein include a coated powder for use in such processes, methods for forming the coated powder, and methods for building an object using the coated powder in an additive manufacturing process.
  • the coated powder includes particles having a base polymer layer formed of a base polymer material surrounded by a coating polymer layer formed of a coating polymer material.
  • the coated powder is susceptible to selective heating, such as dielectric heating through the use of electromagnetic radiation, to improve the strength of the object built.
  • FFF Fusion Fabrication
  • filament refers to feedstock used in an additive manufacturing process that has a slender, threadlike shape.
  • powder coating or “powder coated” or the like terms refer to herein as is a type of coating that is applied, for example, as dry powder and usually applied electrostatically and then cured via heat, electromagnetic radiation such as microwave, or other curing source.
  • the powder may be a thermoplastic, a thermoset polymer, or other like polymer or material.
  • Selective Laser Sintering or “Selective Laser Melting” and like terms, as used herein refers to an additive manufacturing process using a laser to sinter powdered material, pointing the laser into space, and using a 3D model as the pattern, binding the material together to create a solid structure.
  • the powdered material is nylon, polyamide or like materials
  • FIG. 1 illustrates an apparatus 2 for converting a powder 4 into a coated powder 6 that can be used in an additive manufacturing process to build an object having improved structural integrity.
  • the apparatus 2 includes a coating chamber 8 having a side wall 10 and a base 12. Perforations 14 are formed in the base 12 to permit air from a pressurized air source 16 to pass into the coating chamber 8.
  • a nozzle 18 is disposed inside the coating chamber 8 and is fluidly coupled to a coating supply 20.
  • particles of powder 4 are placed at the bottom of the coating chamber 8.
  • the pressurized air source 16 is operated to generate air streams 22 that blow the particles of powder 4 through the coating chamber 8.
  • the coating supply 20 is operated to spray a coating 24 from the nozzle 18 and throughout the coating chamber 8, thereby to coat the particles of powder 4 with the coating 24.
  • positively or negatively charged ions may also be dispersed from the nozzle 18 to facilitate coating of the particles of powder 4 with the coating 24.
  • the coating 24 may be supplied in a liquid phase that subsequently dries and hardens over the powder 4.
  • the apparatus 2 produces the coated powder 6 having a base polymer layer 26 and a coating polymer layer 28, as best shown in FIG. 2 .
  • the materials used to form the base polymer layer 26 and the coating polymer layer 28 of the coated powder 6 permit selective heating during a powder-based additive manufacturing process, thereby promoting inter-layer chain diffusion and bonding so that the resulting build object has improved structural integrity.
  • the materials used for the base polymer layer 26 and the coating polymer layer 28 may be selected based on relative responsiveness to dielectric heating, as well as proximity of melting points and solubility parameters.
  • materials used in the coated powder 6 may be selected so that the coating polymer layer 28 is more susceptible to heating in response to electromagnetic radiation than the base polymer layer 26.
  • a property known as dielectric loss factor (which is also known as the dissipation factor and is represented by the symbol tan ⁇ ) quantifies a material's ability to dissipate applied electromagnetic energy in the form of heat.
  • a material with a higher dielectric loss factor will heat up more in response to an applied electromagnetic field than a material with a lower dielectric loss factor.
  • the coating polymer layer 28 is formed of a coating polymer material having a higher dielectric loss factor than a base polymer material used for the base polymer layer 26.
  • the coating polymer material has a tan ⁇ value at least about 50 times the tan ⁇ value of the base polymer material. Additionally or alternatively, the base polymer material has a tan ⁇ value less than .05 and the coating polymer material may have a tan ⁇ greater than .05.
  • the coated powder 6 further may use materials for the base polymer layer 26 and the coating polymer layer 28 that have similar melting points, which improves strength of the build object formed by build layers of coated powder 6 deposited during the additive manufacturing process.
  • the coating polymer material has a higher dielectric loss factor, and therefore generates heat directly in response to the application of electromagnetic energy.
  • the base polymer material may be selected so that it has a melting point that is proximate to that of the coating polymer material, so that heating of the coating polymer layer 28 by the electromagnetic energy will, in turn, heat at least an outer portion of the base polymer layer 26.
  • This indirect heating of the base polymer layer 26 causes the base polymer layer 26 to remain in the softened and/or molten state for a longer period of time, thereby promoting increased diffusion and bonding between adjacent particles of coated powder 6 after they are deposited on the substrate.
  • the melting points of the base polymer material and the coating polymer material preferably permit formation of a solid and liquid morphology.
  • the base polymer material has a first melting point
  • the coating polymer material has a second melting point
  • the first melting point of the base polymer material is within 20 degrees Celsius of the of the second melting point of the coating polymer material. Materials with melting points within about 20 degrees, or about 18 degrees, or about 15 degrees Celsius have been found to generate sufficient heat to prolong the molten state of the base polymer layer 26 to promote diffusion and bonding between particles of coated powder 6 deposited and heated during additive manufacturing.
  • the materials selected for the base polymer layer 26 and the coating polymer layer 28 further may have compatible solubility parameters, further promoting bonding between adjacent particles of coated powder 6 when used in the additive manufacturing process.
  • the coating polymer material may be immiscible with the base polymer material to prevent phase separation and promote fusion of the base polymer layers of adjacent particles during additive manufacturing.
  • the base polymer material has a first solubility parameter
  • the coating polymer material has a second solubility parameter
  • the second solubility parameter is within about 10 J/cc 0.5 of the first solubility parameter. Materials with solubility parameters within about 10 J/cc 0.5 , or about 8 J/cc 0.5 , or about 5 J/cc 0.5 of each other have been found to advantageously promote intermixing when heated during the additive manufacturing process.
  • suitable base polymer materials include polyethylene, polyethylene terephthalate, polypropylene, polyamides, polyetheretherketone, polyphenylene sulphide, polyetherimide, polystyrene, acrylonitrile/butadiene/styrene, polyacrylates, polyacrylonitrile, polycarbonate, or any mixture thereof.
  • Suitable coating polymer materials include polyvinyl alcohol, polyvinylidene fluoride, polyurethane, polyamide imide, polyamide, polyvinyl chloride, acrylic, cellulose esters, or mixtures thereof.
  • the coating polymer material is particularly responsive to electromagnetic energy in a specific frequency range, such as microwave energy in the GHz range.
  • TABLE 1 compares the dielectric loss factors, melting points, and solubility parameters for a specific example in which the coating polymer material is polyvinyl alcohol and the base polymer material is UltemTM 1010 (polyetherimide): TABLE 1 Material tan ⁇ Tm/Tg (degrees Celsius) Solubility Parameter (J/cc 0.5 ) UltemTM 1010 (polyetherimide) 0.001 186 28 Polyvinyl Alcohol 0.185 200 24
  • the base polymer layer 26 and the coating polymer layer 28 further may have physical characteristics that indicate suitability promoting fusion, bonding, and intermixing.
  • the base polymer layer 26 may have a diameter within a range of about 0.01 to about 0.5 millimeters, or within a range of about 0.05 to about 0.4 millimeters, or within a range of about 0.1 to about 0.3 millimeters.
  • the coating polymer layer 28 may have a thickness within a range of about 1 micron to about 50 microns, or within a range of about 5 microns to about 25 microns, or within a range of about 10 microns to about 20 microns.
  • FIGS. 3-7 illustrate an example of a method for forming an object 90 using particles of coated powder 6, according to the present disclosure.
  • the method begins with depositing a first build layer 102 particles of coated powder 6 on a substrate 104.
  • Each of the particles of coated powder 6 includes a core formed by base polymer layer 26 that is surrounded by the coating polymer layer 28.
  • the particles of coated powder 6 may be formed using the apparatus 2 of FIG. 1 , or may be formed by a different apparatus and/or method.
  • the selected particles of coated powder 6 in the first build layer 102 are melted or sintered using a laser 106.
  • FIG. 5 depicts the selected particles 108 of coated powder 6 of the first build layer 102 after melting or sintering.
  • the method continues as shown in FIG. 6 by depositing a second build layer 110 of particles of coated powder 6 over the first build layer 102, and melting or sintering selected particles of coated powder 6, to form the object 90 with three dimensions.
  • the method includes directing electromagnetic radiation 120 toward the object 90 to promote diffusion and bonding between adjacent particles of coated powder 6. Because at least the coating polymer material is responsive to dielectric heating, it will melt to fill in any voids between adjacent particles of coated powder 6.
  • the electromagnetic radiation 120 is provided by a heating source 122 that is controlled to direct the electromagnetic radiation 120 to selected areas of the object 90 or the entire object 90. A duration during which the electromagnetic radiation 120 is applied may also be controlled to strengthen one or more localized areas of the object 90, or the entire object 90.
  • the electromagnetic radiation 120 in one example, can be microwaves having frequencies in a range between 300 MHz and 300 GHz.
  • the coating polymer material has a high dielectric loss factor and is susceptible to microwave radiation, and thus dielectric heating.
  • a frequency of the electromagnetic radiation may be selected so that only the coating polymer layer 28 is melted directly in response to the electromagnetic radiation.
  • the base polymer material may have a melting point near that of the coating polymer material, so that the base polymer layer 26 at least partially melts in response to heating of the coating polymer layer 28.
  • the coating polymer layer 28 will directly melt and the base polymer layer 26 will indirectly melt in response to the electromagnetic radiation 120.
  • the electromagnetic radiation 120 may directly heat both the coating polymer layer 28 and the base polymer layer 26. In either case, melted portions of the base polymer layer 26 in adjacent particles may fuse together, preventing formation of voids between adjacent particles and promoting structural integrity of the object built.
  • FIG. 7 illustrates the final object 90, with all un-melted or un-sintered particles of coated powder 6 removed from the substrate 104.
  • the resulting object 90 has no voids between particles or build layers.

Abstract

A coated powder for use in additive manufacturing includes a base polymer layer formed of a base polymer material and a coating polymer layer formed of a coating polymer material. At least the coating polymer material is susceptible to dielectric heating in response to electromagnetic radiation, thereby promoting fusion between adjacent particles of coated powder that are deposited during the additive manufacturing process. Specifically, when electromagnetic radiation is applied to at least an interface area between adjacent particles of coated powder, the polymer coating layer melts to diffuse across the interface area, thereby preventing formation of voids. The base polymer material and the coating polymer material also may have similar melting points and compatible solubility parameters to further promote fusion between particles.

Description

    Field
  • The present disclosure relates to additive manufacturing apparatus and methods, and particularly to powder-based additive manufacturing. The additive manufacturing process disclosed herein can be useful in producing parts including environmental control ducts, door panels, tools, jigs, fixtures, and the like. Examples of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive, and for example a casing used for auxiliary power units (APUs).
    • Background
  • Parts and other components may be manufactured using various manufacturing techniques depending on the performance requirements of the parts and the availability of manufacturing equipment. Selective laser sintering (SLS) and selective laser melting (SLM) are powder-based additive manufacturing techniques that may be used to build components, in which a layer of powder is maintained at an elevated temperature and is selectively sintered or melted using a laser. Once a first build layer has been formed, successive build layers are formed on top of the first build layer using a similar process until the desired three-dimensional object is complete. Powders used in these processes are typically formed of thermoplastic, polycarbonate, or other similarly configured material. Powder-based additive manufacturing, such as SLS and SLM, may introduce voids between powder particles within a build layer and between adjacent build layers formed during the process, thereby resulting in an object with reduced structural integrity.
    • Summary
  • According to one aspect of the present disclosure, a coated powder is provided for use in an additive manufacturing process. The coated powder includes a base polymer layer formed of a base polymer material having a first dielectric loss factor, and a coating polymer layer surrounding the base polymer layer and formed of a coating polymer material having a second dielectric loss factor, wherein the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
  • According to another aspect of the present disclosure, a method of fabricating a coated powder for use in an additive manufacturing process includes advancing a plurality of powder particles through a chamber, each of the plurality of powder particles being formed of a base polymer material, applying a liquid coating to an exterior of each of the plurality of powder particles, the liquid coating being formed of a coating polymer material, and drying the liquid coating on the plurality of powder particles to form a plurality of coated powder particles. Each of the plurality of coated powder particles comprises a base polymer layer formed by the powder particle and a coating polymer layer formed by the liquid coating after drying.
  • According to a further aspect of the present disclosure, a method of fabricating an object by fused powder fabrication includes forming a coated powder by advancing a plurality of powder particles through a chamber, each of the plurality of powder particles being formed of a base polymer material, applying a liquid coating to an exterior of each of the plurality of powder particles, the liquid coating being formed of a coating polymer material, and drying the liquid coating on the plurality of powder particles to form a plurality of coated powder particles, so that each of the plurality of coated powder particles comprises a base polymer layer formed by the powder particle and a coating polymer layer formed by the liquid coating after drying. The method further includes depositing the coated powder in a first build layer on a substrate, heating selected portions of the first build layer, depositing the coated powder in a second build layer on the substrate and over the first build layer, heating selected portions of the second build layer, and dielectrically heating at least the coating polymer layer of the coated powder in the selected portions of the first and second build layers using electromagnetic radiation, thereby to fuse adjacent particles of the coated powder across an interface area.
  • The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
    • Brief Description of the Drawings
  • The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of illustrative examples of the present disclosure when read in conjunction with the accompanying drawings, wherein:
    • FIG. 1 is a diagrammatic illustration of apparatus for converting powder particles into coated powder particles.
    • FIG. 2 is an illustration of exemplary coated powder particles formed according to a method of fabricating a coated powder.
    • FIGS. 3-7 illustrate an example of a method for forming an object using particles of coated powder, according to the present disclosure.
    Detailed Description
  • The following detailed description is directed to powder-based additive manufacturing technologies, such as selective laser sintering (SLS) or selective laser melting (SLM). The examples disclosed herein include a coated powder for use in such processes, methods for forming the coated powder, and methods for building an object using the coated powder in an additive manufacturing process. The coated powder includes particles having a base polymer layer formed of a base polymer material surrounded by a coating polymer layer formed of a coating polymer material. The coated powder is susceptible to selective heating, such as dielectric heating through the use of electromagnetic radiation, to improve the strength of the object built.
    • Definitions
  • "Fused Filament Fabrication (FFF) is an additive manufacturing technology used for building up of layers to form products and for example, three-dimensional products, prototypes or models. The process can be rapid for quick prototyping and manufacturing to build layer after layer of molten material to create a model, product or like object.
  • As used herein, the term "filament" refers to feedstock used in an additive manufacturing process that has a slender, threadlike shape.
  • The term "powder coating" or "powder coated" or the like terms refer to herein as is a type of coating that is applied, for example, as dry powder and usually applied electrostatically and then cured via heat, electromagnetic radiation such as microwave, or other curing source. The powder may be a thermoplastic, a thermoset polymer, or other like polymer or material.
  • The phrase "Selective Laser Sintering" or "Selective Laser Melting" and like terms, as used herein refers to an additive manufacturing process using a laser to sinter powdered material, pointing the laser into space, and using a 3D model as the pattern, binding the material together to create a solid structure. Usually, the powdered material is nylon, polyamide or like materials
  • References are made to the accompanying drawings that form a part hereof, and which are shown by way of illustration, specific embodiments, or examples. Like numerals represent like elements through the several figures.
  • Turning now to the figures, FIG. 1 illustrates an apparatus 2 for converting a powder 4 into a coated powder 6 that can be used in an additive manufacturing process to build an object having improved structural integrity. Specifically, the apparatus 2 includes a coating chamber 8 having a side wall 10 and a base 12. Perforations 14 are formed in the base 12 to permit air from a pressurized air source 16 to pass into the coating chamber 8. A nozzle 18 is disposed inside the coating chamber 8 and is fluidly coupled to a coating supply 20.
  • In operation, particles of powder 4 are placed at the bottom of the coating chamber 8. The pressurized air source 16 is operated to generate air streams 22 that blow the particles of powder 4 through the coating chamber 8. Simultaneously, the coating supply 20 is operated to spray a coating 24 from the nozzle 18 and throughout the coating chamber 8, thereby to coat the particles of powder 4 with the coating 24. In some examples, positively or negatively charged ions may also be dispersed from the nozzle 18 to facilitate coating of the particles of powder 4 with the coating 24. The coating 24 may be supplied in a liquid phase that subsequently dries and hardens over the powder 4. Ultimately, the apparatus 2 produces the coated powder 6 having a base polymer layer 26 and a coating polymer layer 28, as best shown in FIG. 2.
  • The materials used to form the base polymer layer 26 and the coating polymer layer 28 of the coated powder 6 permit selective heating during a powder-based additive manufacturing process, thereby promoting inter-layer chain diffusion and bonding so that the resulting build object has improved structural integrity. As discussed in greater detail below, the materials used for the base polymer layer 26 and the coating polymer layer 28 may be selected based on relative responsiveness to dielectric heating, as well as proximity of melting points and solubility parameters.
  • Regarding responsiveness to dielectric heating, materials used in the coated powder 6 may be selected so that the coating polymer layer 28 is more susceptible to heating in response to electromagnetic radiation than the base polymer layer 26. A property known as dielectric loss factor (which is also known as the dissipation factor and is represented by the symbol tan δ) quantifies a material's ability to dissipate applied electromagnetic energy in the form of heat. A material with a higher dielectric loss factor will heat up more in response to an applied electromagnetic field than a material with a lower dielectric loss factor. To focus heating at the external surface of the coated powder 6, the coating polymer layer 28 is formed of a coating polymer material having a higher dielectric loss factor than a base polymer material used for the base polymer layer 26. In some examples, the coating polymer material has a tan δ value at least about 50 times the tan δ value of the base polymer material. Additionally or alternatively, the base polymer material has a tan δ value less than .05 and the coating polymer material may have a tan δ greater than .05.
  • The coated powder 6 further may use materials for the base polymer layer 26 and the coating polymer layer 28 that have similar melting points, which improves strength of the build object formed by build layers of coated powder 6 deposited during the additive manufacturing process. As noted above, the coating polymer material has a higher dielectric loss factor, and therefore generates heat directly in response to the application of electromagnetic energy. The base polymer material may be selected so that it has a melting point that is proximate to that of the coating polymer material, so that heating of the coating polymer layer 28 by the electromagnetic energy will, in turn, heat at least an outer portion of the base polymer layer 26. This indirect heating of the base polymer layer 26 causes the base polymer layer 26 to remain in the softened and/or molten state for a longer period of time, thereby promoting increased diffusion and bonding between adjacent particles of coated powder 6 after they are deposited on the substrate. The melting points of the base polymer material and the coating polymer material preferably permit formation of a solid and liquid morphology. In some examples, the base polymer material has a first melting point, the coating polymer material has a second melting point, and the first melting point of the base polymer material is within 20 degrees Celsius of the of the second melting point of the coating polymer material. Materials with melting points within about 20 degrees, or about 18 degrees, or about 15 degrees Celsius have been found to generate sufficient heat to prolong the molten state of the base polymer layer 26 to promote diffusion and bonding between particles of coated powder 6 deposited and heated during additive manufacturing.
  • The materials selected for the base polymer layer 26 and the coating polymer layer 28 further may have compatible solubility parameters, further promoting bonding between adjacent particles of coated powder 6 when used in the additive manufacturing process. For example, the coating polymer material may be immiscible with the base polymer material to prevent phase separation and promote fusion of the base polymer layers of adjacent particles during additive manufacturing. In some examples, the base polymer material has a first solubility parameter, the coating polymer material has a second solubility parameter, and the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter. Materials with solubility parameters within about 10 J/cc0.5, or about 8 J/cc0.5, or about 5 J/cc0.5 of each other have been found to advantageously promote intermixing when heated during the additive manufacturing process.
  • In view of the foregoing considerations, suitable base polymer materials include polyethylene, polyethylene terephthalate, polypropylene, polyamides, polyetheretherketone, polyphenylene sulphide, polyetherimide, polystyrene, acrylonitrile/butadiene/styrene, polyacrylates, polyacrylonitrile, polycarbonate, or any mixture thereof.
  • Suitable coating polymer materials include polyvinyl alcohol, polyvinylidene fluoride, polyurethane, polyamide imide, polyamide, polyvinyl chloride, acrylic, cellulose esters, or mixtures thereof. Other examples of suitable coating polymer materials include materials and solvents that contain -OH, -NH, C=O, -N=O functional groups with a high dielectric loss factor. Further examples of suitable coating polymer materials include polyacrylonitrile (tan δ=.1 at 60 Hz), polyethylene glycol, or mixtures thereof. In some examples, the coating polymer material is particularly responsive to electromagnetic energy in a specific frequency range, such as microwave energy in the GHz range.
  • TABLE 1 compares the dielectric loss factors, melting points, and solubility parameters for a specific example in which the coating polymer material is polyvinyl alcohol and the base polymer material is Ultem™ 1010 (polyetherimide): TABLE 1
    Material tan δ Tm/Tg (degrees Celsius) Solubility Parameter (J/cc0.5)
    Ultem™ 1010 (polyetherimide) 0.001 186 28
    Polyvinyl Alcohol 0.185 200 24
  • In this example, the use of Ultem™ 1010 (polyetherimide) as the base polymer material and polyvinyl alcohol as the coating polymer material is advantageous because polyvinyl alcohol has a high dielectric loss factor (tan δ=0.185 in the MHz-GHz frequency range), relative to Ultem™ 1010 (tan δ-0.001 in the MHz-GHz frequency range), the melting points of the two materials are 14 degrees Celsius apart, and the solubility parameters are close, indicating compatibility.
  • In addition to chemical characteristics, the base polymer layer 26 and the coating polymer layer 28 further may have physical characteristics that indicate suitability promoting fusion, bonding, and intermixing. For example, the base polymer layer 26 may have a diameter within a range of about 0.01 to about 0.5 millimeters, or within a range of about 0.05 to about 0.4 millimeters, or within a range of about 0.1 to about 0.3 millimeters. The coating polymer layer 28 may have a thickness within a range of about 1 micron to about 50 microns, or within a range of about 5 microns to about 25 microns, or within a range of about 10 microns to about 20 microns.
  • FIGS. 3-7 illustrate an example of a method for forming an object 90 using particles of coated powder 6, according to the present disclosure. As best shown in FIG. 3, the method begins with depositing a first build layer 102 particles of coated powder 6 on a substrate 104. Each of the particles of coated powder 6 includes a core formed by base polymer layer 26 that is surrounded by the coating polymer layer 28. The particles of coated powder 6 may be formed using the apparatus 2 of FIG. 1, or may be formed by a different apparatus and/or method. As shown in FIG. 4, the selected particles of coated powder 6 in the first build layer 102 are melted or sintered using a laser 106. FIG. 5 depicts the selected particles 108 of coated powder 6 of the first build layer 102 after melting or sintering. The method continues as shown in FIG. 6 by depositing a second build layer 110 of particles of coated powder 6 over the first build layer 102, and melting or sintering selected particles of coated powder 6, to form the object 90 with three dimensions.
  • As further shown in FIG. 6, the method includes directing electromagnetic radiation 120 toward the object 90 to promote diffusion and bonding between adjacent particles of coated powder 6. Because at least the coating polymer material is responsive to dielectric heating, it will melt to fill in any voids between adjacent particles of coated powder 6. The electromagnetic radiation 120 is provided by a heating source 122 that is controlled to direct the electromagnetic radiation 120 to selected areas of the object 90 or the entire object 90. A duration during which the electromagnetic radiation 120 is applied may also be controlled to strengthen one or more localized areas of the object 90, or the entire object 90. Further, the electromagnetic radiation 120, in one example, can be microwaves having frequencies in a range between 300 MHz and 300 GHz. In this example, the coating polymer material has a high dielectric loss factor and is susceptible to microwave radiation, and thus dielectric heating.
  • Since the coating polymer material has a higher dielectric loss factor, and the base polymer material has a lower dielectric loss factor, a frequency of the electromagnetic radiation may be selected so that only the coating polymer layer 28 is melted directly in response to the electromagnetic radiation. Additionally, the base polymer material may have a melting point near that of the coating polymer material, so that the base polymer layer 26 at least partially melts in response to heating of the coating polymer layer 28. Thus, the coating polymer layer 28 will directly melt and the base polymer layer 26 will indirectly melt in response to the electromagnetic radiation 120. In other examples, the electromagnetic radiation 120 may directly heat both the coating polymer layer 28 and the base polymer layer 26. In either case, melted portions of the base polymer layer 26 in adjacent particles may fuse together, preventing formation of voids between adjacent particles and promoting structural integrity of the object built.
  • In examples where the coating polymer material and the base polymer material have compatible solubility parameters (see the non-limiting example in Table 1), melting of both the coating polymer layer 28 and the base polymer layer 26 creates a homogenous mixture, and therefore no phase separation occurs when the melted layers subsequently cool and harden.
  • FIG. 7 illustrates the final object 90, with all un-melted or un-sintered particles of coated powder 6 removed from the substrate 104. The resulting object 90 has no voids between particles or build layers.
  • Further, the disclosure comprises embodiments or examples according to the following clauses:
    1. 1. A coated powder (6) for use in an additive manufacturing process, the coated powder (6) comprising:
      • a base polymer layer (26) formed of a base polymer material having a first dielectric loss factor; and
      • a coating polymer layer (28) surrounding the base polymer layer (26) and formed of a coating polymer material having a second dielectric loss factor, wherein the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
    2. 2. The coated powder (6) of clause 1, in which the base polymer material has a first melting point, the coating polymer material has a second melting point, and the first melting point is within about 20 degrees Celsius of the second melting point.
    3. 3. The coated powder (6) of clause 2, in which the base polymer material has a first solubility parameter, the coating polymer material has a second solubility parameter, and the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
    4. 4. The coated powder (6) of clause 1, in which the base polymer material has a first solubility parameter, the coating polymer material has a second solubility parameter, and the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
    5. 5. The coated powder (6) of any of clauses 1 to 4, in which the base polymer material comprises polyetherimide and the coating polymer material comprises polyvinyl alcohol.
    6. 6. The coated powder (6) of any of clauses 1 to 5, in which the base polymer layer (26) has a diameter of from about 0.1 to about 5 millimeters, and the coating polymer layer (28) has a thickness of from about 1 to about 1,000 microns.
    7. 7. A method of fabricating a coated powder (6) for use in an additive manufacturing process, the method comprising:
      • advancing a plurality of powder particles (4) through a chamber (8), each of the plurality of powder particles (4) being formed of a base polymer material;
      • applying a liquid coating (24) to an exterior of each of the plurality of powder particles (4), the liquid coating (24) being formed of a coating polymer material; and
      • drying the liquid coating (24) on the plurality of powder particles (4) to form a plurality of coated powder particles (6);
      • wherein each of the plurality of coated powder particles (6) comprises a base polymer layer (26) formed by the powder particle (4) and a coating polymer layer (28) formed by the liquid coating (24) after drying.
    8. 8. The method of clause 7, in which advancing the plurality of powder particles (4) through the chamber (8) comprises providing the chamber (8) with perforations (14) and directing pressurized air through the perforations (14) to form air streams (22) through the chamber (8).
    9. 9. The method of clause 8, in which applying the liquid coating (24) to the exterior of each of the plurality of powder particles (4) comprises spraying the liquid coating (24) from a nozzle (18) disposed in the chamber (8).
    10. 10. The method any of clauses 7 to 9, in which:
      • the base polymer material has a first dielectric loss factor;
      • the coating polymer material has a second dielectric loss factor; and
      • the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
    11. 11. The method of any of clauses 7 to 10, in which:
      • the base polymer material has a first melting point;
      • the coating polymer material has a second melting point; and
      • the first melting point is within about 20 degrees Celsius of the of the second melting point.
    12. 12. The method of any of clauses 7 to 11, in which:
      • the base polymer material has a first solubility parameter;
      • the coating polymer material has a second solubility parameter; and
      • the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
    13. 13. The method of any of clauses 7 to 12, in which the base polymer material comprises polyetherimide and the coating polymer material comprises polyvinyl alcohol.
    14. 14. The method of any of clauses 7 to 13, in which the base polymer layer (26) has a diameter of from about 0.1 to about 5 millimeters, and the coating polymer layer (28) has a thickness of from about 1 to about 1,000 microns.
    15. 15. A method of fabricating an object (50) by fused powder fabrication, comprising:
      • forming a coated powder (6) by:
        • advancing a plurality of powder particles (4) through a chamber (8), each of the plurality of powder particles (4) being formed of a base polymer material;
        • applying a liquid coating (24) to an exterior of each of the plurality of powder particles (4), the liquid coating (24) being formed of a coating polymer material; and
        • drying the liquid coating (24) on the plurality of powder particles (4) to form a plurality of coated powder particles (6);
        • wherein each of the plurality of coated powder particles (6) comprises a base polymer layer (26) formed by the powder particle (4) and a coating polymer layer (28) formed by the liquid coating (24) after drying;
      • depositing the coated powder (6) in a first build layer (52) on a substrate (104);
      • heating selected portions of the first build layer (52);
      • depositing the coated powder in a second build layer (60) on the substrate (104) and over the first build layer (52);
      • heating selected portions of the second build layer (60); and
      • dielectrically heating at least the coating polymer layer of the coated powder (6) in the selected portions of the first and second build layers (52, 60) using electromagnetic radiation (120), to fuse adjacent particles of the coated powder (6) across an interface area.
    16. 16. The method of clause 15, in which:
      • the base polymer material has a first dielectric loss factor;
      • the coating polymer material has a second dielectric loss factor; and
      • the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
    17. 17. The method of clauses 15 or 16, in which:
      • the base polymer material has a first melting point;
      • the coating polymer material has a second melting point; and
      • the first melting point is within about 20 degrees Celsius of the of the second melting point.
    18. 18. The method of any of clauses 15 to 17, in which:
      • the base polymer material has a first solubility parameter;
      • the coating polymer material has a second solubility parameter; and
      • the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
    19. 19. The method of any of clauses 15 to 18, in which the base polymer material comprises polyetherimide and the coating polymer material comprises polyvinyl alcohol.
    20. 20. The method of any of clauses 15 to 19, in which dielectrically heating at least the coating polymer layer of the coated powder in the selected portions of the first and second build layers comprises applying the electromagnetic radiation (120) in a microwave range of frequencies.
  • It should be understood that the drawings are not necessarily drawn to scale and that the disclosed examples are sometimes illustrated schematically. It is to be further appreciated that the following detailed description is merely exemplary in nature and is not intended to limit the disclosure the application and uses thereof. Hence, although the present disclosure is, for convenience of explanation, depicted and described as certain illustrative examples, it will be appreciated that it can be implemented in various other types of examples and in various other systems and environments.

Claims (15)

  1. A coated powder (6) for use in an additive manufacturing process, the coated powder (6) comprising:
    a base polymer layer (26) formed of a base polymer material having a first dielectric loss factor; and
    a coating polymer layer (28) surrounding the base polymer layer (26) and formed of a coating polymer material having a second dielectric loss factor, wherein the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
  2. The coated powder (6) of claim 1, in which the base polymer material has a first melting point, the coating polymer material has a second melting point, and the first melting point is within about 20 degrees Celsius of the second melting point.
  3. The coated powder (6) of claims 1 or 2, in which the base polymer material has a first solubility parameter, the coating polymer material has a second solubility parameter, and the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
  4. The coated powder (6) of any of claims 1 to 3, in which the base polymer material comprises polyetherimide and the coating polymer material comprises polyvinyl alcohol.
  5. The coated powder (6) of any of claims 1 to 4, in which the base polymer layer (26) has a diameter of from about 0.1 to about 5 millimeters, and the coating polymer layer (28) has a thickness of from about 1 to about 1,000 microns.
  6. A method of fabricating a coated powder (6) for use in an additive manufacturing process, the method comprising:
    advancing a plurality of powder particles (4) through a chamber (8), each of the plurality of powder particles (4) being formed of a base polymer material;
    applying a liquid coating (24) to an exterior of each of the plurality of powder particles (4), the liquid coating (24) being formed of a coating polymer material; and
    drying the liquid coating (24) on the plurality of powder particles (4) to form a plurality of coated powder particles (6);
    wherein each of the plurality of coated powder particles (6) comprises a base polymer layer (26) formed by the powder particle (4) and a coating polymer layer (28) formed by the liquid coating (24) after drying.
  7. The method of claim 6, in which advancing the plurality of powder particles (4) through the chamber (8) comprises providing the chamber (8) with perforations (14) and directing pressurized air through the perforations (14) to form air streams (22) through the chamber (8).
  8. The method of claims 6 or 7, in which applying the liquid coating (24) to the exterior of each of the plurality of powder particles (4) comprises spraying the liquid coating (24) from a nozzle (18) disposed in the chamber (8).
  9. The method any of claims 6 to 8, in which:
    the base polymer material has a first dielectric loss factor;
    the coating polymer material has a second dielectric loss factor; and
    the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material.
  10. The method of any of claims 6 to 9, in which:
    the base polymer material has a first melting point;
    the coating polymer material has a second melting point; and
    the first melting point is within about 20 degrees Celsius of the of the second melting point.
  11. The method of any of claims 6 to 10, in which:
    the base polymer material has a first solubility parameter;
    the coating polymer material has a second solubility parameter; and
    the second solubility parameter is within about 10 J/cc0.5 of the first solubility parameter.
  12. The method of any of claims 6 to 11, in which the base polymer material comprises polyetherimide and the coating polymer material comprises polyvinyl alcohol.
  13. The method of any of claims 6 to 12, in which the base polymer layer (26) has a diameter of from about 0.1 to about 5 millimeters, and the coating polymer layer (28) has a thickness of from about 1 to about 1,000 microns.
  14. A method of fabricating an object (50) by fused powder fabrication, comprising:
    forming a coated powder (6) by:
    advancing a plurality of powder particles (4) through a chamber (8), each of the plurality of powder particles (4) being formed of a base polymer material;
    applying a liquid coating (24) to an exterior of each of the plurality of powder particles (4), the liquid coating (24) being formed of a coating polymer material; and
    drying the liquid coating (24) on the plurality of powder particles (4) to form a plurality of coated powder particles (6);
    wherein each of the plurality of coated powder particles (6) comprises a base polymer layer (26) formed by the powder particle (4) and a coating polymer layer (28) formed by the liquid coating (24) after drying;
    depositing the coated powder (6) in a first build layer (52) on a substrate (104);
    heating selected portions of the first build layer (52);
    depositing the coated powder in a second build layer (60) on the substrate (104) and over the first build layer (52);
    heating selected portions of the second build layer (60); and
    dielectrically heating at least the coating polymer layer of the coated powder (6) in the selected portions of the first and second build layers (52, 60) using electromagnetic radiation (120), to fuse adjacent particles of the coated powder (6) across an interface area.
  15. The method of claim 14, in which dielectrically heating at least the coating polymer layer of the coated powder in the selected portions of the first and second build layers comprises applying the electromagnetic radiation (120) in a microwave range of frequencies.
EP21150187.9A 2020-01-08 2021-01-05 Coated powder for additive manufacturing Active EP3848182B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US16/737,626 US11904533B2 (en) 2020-01-08 2020-01-08 Coated powder for improved additive manufacturing parts

Publications (2)

Publication Number Publication Date
EP3848182A1 true EP3848182A1 (en) 2021-07-14
EP3848182B1 EP3848182B1 (en) 2023-03-22

Family

ID=74103938

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21150187.9A Active EP3848182B1 (en) 2020-01-08 2021-01-05 Coated powder for additive manufacturing

Country Status (5)

Country Link
US (2) US11904533B2 (en)
EP (1) EP3848182B1 (en)
JP (1) JP2021109443A (en)
CN (1) CN113087928A (en)
ES (1) ES2942904T3 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040038611A1 (en) * 2002-08-26 2004-02-26 Satoru Amou Low dielectric loss tangent films and wiring films
US20060251826A1 (en) * 2003-02-18 2006-11-09 Rolf Pfeifer Method for coating particles for generative prototyping processes
US20160200011A1 (en) * 2015-01-13 2016-07-14 Empire Technology Development Llc Spatial heat treatment of additively manufactured objects
WO2018148359A1 (en) * 2017-02-08 2018-08-16 Jabil Inc. Core and shell polymers for 3d-printing

Family Cites Families (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1167436A (en) 1966-08-19 1969-10-15 Grace W R & Co Novel Sheet Material
GB1200890A (en) 1966-12-19 1970-08-05 Ici Ltd Method of manufacturing a coated sheet material
US3880116A (en) * 1974-02-14 1975-04-29 Arnar Stone Lab Particle coating apparatus
US4784878A (en) * 1987-04-06 1988-11-15 Damrow Company, Inc. Spray drying method and apparatus for concurrent particle coating
US5248550A (en) * 1989-02-13 1993-09-28 Lockheed Corporation Encapsulation of thermoplastic particles for production of composites
ES2259019T3 (en) * 2001-09-18 2006-09-16 Aeromatic-Fielder Ag PROCEDURE FOR COVERING PARTICLES.
CN101304816B (en) 2005-11-15 2012-12-12 阿克佐诺贝尔国际涂料股份有限公司 Process for preparation of a multilayer coating sheet
WO2011160181A1 (en) 2010-06-23 2011-12-29 Oem Nutech Pty Ltd A coated laminate material and a method of fabricating therefor
US9833949B2 (en) 2011-08-29 2017-12-05 Impossible Objects, Inc. Apparatus for fabricating three-dimensional printed composites
US20140272430A1 (en) * 2013-03-15 2014-09-18 Sabic Innovative Plastics Ip B.V. Process of making dispersed polyetherimide micronized particles and process of coating and further forming of these particles products made therefrom
US20160297104A1 (en) 2013-11-19 2016-10-13 Guill Tool & Engineering Coextruded, multilayer and multicomponent 3d printing inputs field
CN105849185A (en) 2013-11-26 2016-08-10 科腾聚合物美国有限责任公司 Laser sintering powder, laser sintering article, and a method of making a laser sintering article
WO2015130401A2 (en) 2013-12-26 2015-09-03 Texas Tech University System Microwave-induced localized heating of cnt filled polymer composites for enhanced inter-bead diffusive bonding of fused filament fabricated parts
CN106132702B (en) 2014-03-31 2019-02-15 沙特基础工业全球技术有限公司 Multi-layer sheet, manufacturing method and the product formed by it
WO2016068899A1 (en) 2014-10-29 2016-05-06 Hewlett-Packard Development Company, L.P. Three-dimensional (3d) printing method
EP3268218A1 (en) 2015-03-09 2018-01-17 Transitions Optical, Inc. Method and assembly for coating a substrate
US10710353B2 (en) 2015-09-11 2020-07-14 Arizona Board Of Regents On Behalf Of Arizona State University Systems and methods for laser preheating in connection with fused deposition modeling
EP3377305B1 (en) 2015-11-17 2023-01-25 Zephyros Inc. Additive manufacturing materials system
WO2018094276A1 (en) 2016-11-18 2018-05-24 Massachusetts Institute Of Technology Multimaterial 3d-printing with functional fiber
CN111770942A (en) * 2018-03-07 2020-10-13 丸善石油化学株式会社 Core-shell type polymer microparticle, particle dispersion, and method for producing microparticle
KR102363986B1 (en) * 2018-11-16 2022-02-16 주식회사 엘지화학 Core-shell copolymer, method for preparing the core-shell copolymer and thermoplastic resin composition comprising the core-shell copolymer

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040038611A1 (en) * 2002-08-26 2004-02-26 Satoru Amou Low dielectric loss tangent films and wiring films
US20060251826A1 (en) * 2003-02-18 2006-11-09 Rolf Pfeifer Method for coating particles for generative prototyping processes
US20160200011A1 (en) * 2015-01-13 2016-07-14 Empire Technology Development Llc Spatial heat treatment of additively manufactured objects
WO2018148359A1 (en) * 2017-02-08 2018-08-16 Jabil Inc. Core and shell polymers for 3d-printing

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
ANONYMOUS: "Electrical Properties of Plastics", 17 July 2019 (2019-07-17), XP055808215, Retrieved from the Internet <URL:https://web.archive.org/web/20190717232331/https://members.tm.net/lapointe/plastics.htm> [retrieved on 20210527] *
BUR ET AL: "Dielectric properties of polymers at microwave frequencies: a review", POLYMER, ELSEVIER SCIENCE PUBLISHERS B.V, GB, vol. 26, no. 7, 1 July 1985 (1985-07-01), pages 963 - 977, XP024117585, ISSN: 0032-3861, [retrieved on 19850701], DOI: 10.1016/0032-3861(85)90216-2 *
POLYMERDATABASE: "Prediction of Solubility Parameters A Comparison of four Group Contribution Methods", 1 June 2015 (2015-06-01), XP055687364, Retrieved from the Internet <URL:http://polymerdatabase.com/pdf/crow_sol_par_June2015.pdf> [retrieved on 20200420] *

Also Published As

Publication number Publication date
US11904533B2 (en) 2024-02-20
JP2021109443A (en) 2021-08-02
CN113087928A (en) 2021-07-09
ES2942904T3 (en) 2023-06-07
EP3848182B1 (en) 2023-03-22
US20210206053A1 (en) 2021-07-08
US20240100770A1 (en) 2024-03-28

Similar Documents

Publication Publication Date Title
US9937557B2 (en) Continuous linear production in a selective laser sintering system
RU2759921C2 (en) Method for obtaining thermoplastic composite structures and prepreg tape used between them
US20150224575A1 (en) Sinter mold material, sintering and molding method, sinter mold object, and sintering and molding apparatus
EP3848181A1 (en) Coated filament for improved additive manufacturing parts
US9617394B2 (en) Coated particles for forming of continuous polymeric or metallic layers
JP2014058157A (en) Production method for forming three-dimensional object having small warp by lamination system using cooling component
EP3848182A1 (en) Coated powder for additive manufacturing
KR101408413B1 (en) Manufacturing method and apparatus for a hollow molded part
EP3848184B1 (en) Coated sheets for improved additive manufacturing parts
EP3460810B1 (en) Advanced high voltage capacitance graded bushing
US20060119017A1 (en) Method for making ceramic work piece and cermet work piece
EP3936299A1 (en) Resin molding method
Niese et al. Fast and flexible production of mechatronic integrated devices by means of additive manufacturing
JP7137227B2 (en) Preforming apparatus, preforming method, resin molding system, and resin molding method
EP3771550B1 (en) Plasma-treated powders for additive manufacturing
WO2023013428A1 (en) Resin molding method
Borges 3D LDS components: New opportunities in PCB layout and production
Scholl et al. Electrostatic Powder Coating as a Novel Process for High‐Voltage Insulation Applications
CN114346261A (en) 3D printing method and system
CN113573865A (en) Resin molding method
CN114585468A (en) Methods and systems for additive manufacturing of electrical devices

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION HAS BEEN PUBLISHED

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20220112

RBV Designated contracting states (corrected)

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: GRANT OF PATENT IS INTENDED

INTG Intention to grant announced

Effective date: 20221215

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE PATENT HAS BEEN GRANTED

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

RAP3 Party data changed (applicant data changed or rights of an application transferred)

Owner name: THE BOEING COMPANY

REG Reference to a national code

Ref country code: GB

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: CH

Ref legal event code: EP

REG Reference to a national code

Ref country code: DE

Ref legal event code: R096

Ref document number: 602021001646

Country of ref document: DE

REG Reference to a national code

Ref country code: IE

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: AT

Ref legal event code: REF

Ref document number: 1555041

Country of ref document: AT

Kind code of ref document: T

Effective date: 20230415

REG Reference to a national code

Ref country code: ES

Ref legal event code: FG2A

Ref document number: 2942904

Country of ref document: ES

Kind code of ref document: T3

Effective date: 20230607

P01 Opt-out of the competence of the unified patent court (upc) registered

Effective date: 20230516

REG Reference to a national code

Ref country code: LT

Ref legal event code: MG9D

REG Reference to a national code

Ref country code: NL

Ref legal event code: MP

Effective date: 20230322

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: RS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: NO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230622

Ref country code: LV

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: LT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: HR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

REG Reference to a national code

Ref country code: AT

Ref legal event code: MK05

Ref document number: 1555041

Country of ref document: AT

Kind code of ref document: T

Effective date: 20230322

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: NL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: GR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230623

Ref country code: FI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SM

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: RO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: PT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230724

Ref country code: EE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: AT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: PL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: IS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230722

REG Reference to a national code

Ref country code: DE

Ref legal event code: R097

Ref document number: 602021001646

Country of ref document: DE

P01 Opt-out of the competence of the unified patent court (upc) registered

Effective date: 20231205

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: DK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

Ref country code: CZ

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230322

26N No opposition filed

Effective date: 20240102

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: ES

Payment date: 20240201

Year of fee payment: 4